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Home My WebLink About2017-03-23 Duke NC Waste Management Plan 2017 Update3191 Pine Hall Road Walnut Cove, NC 27009 336-215-4576 Page 1 of 2 March 23, 2017 North Carolina Department of Environmental Quality Division of Waste Management Solid Waste Section 1646 Mail Service Center Raleigh, North Carolina 27699 Attn: Ms. Shawn McKee (submitted electronically) Re: Duke Energy Management Plan 2017 Update Permit No. Various 526 South Church Street Charlotte, North Carolina 28202 Dear Ms. McKee, Attached you will find the Waste Management Plan for Duke Energy (Duke) Coal Combustion Residual Industrial Landfill Facilities. As previously discussed with the Section, waste management at Duke facilities operates as a system thereby resulting in a better representation as a combined Waste Management Plan. This Solid Waste Management Plan pertains to landfills at operational coal combustion facilities: • Allen Steam Station Retired Ash Basin Landfill Permit No. 3612 • Belews Creek Steam Station Craig Road Ash Landfill Permit No. 8504 • Belews Flue Gas Desulfurization Residue Landfill Permit No. 8505 • Cliffside Steam Station Coal Combustion Products Landfill Permit No. 8106 • Marshall Steam Station FGD Residue Landfill, Phase I, Cell 1 Permit No. 1809 • Marshall Steam Station Industrial Landfill #1 Permit No. 1812 • Mayo Steam Electric Plant Coal Combustion Product Landfill Permit No. 7305 • Roxboro Steam Electric Plant Landfill Permit No. 7302 And facilities that have landfills to support closure of ash basins at retired coal combustion facilities: • Dan River Steam Station Landfill (Under Construction) Permit No. 7906 • Sutton Steam Electric Plant Landfill (Under Construction) Permit No. 6512 This plan is being submitted as courtesy in accordance with GS 130A-309.09D. Page 2 of 2 If you need additional information in regards to this submittal please do not hesitate to call or email, 336- 215-4576 or kimberlee.witt@duke-energy.com. Regards, Kimberlee Witt, PE Environmental Services Attachments: North Carolina Ten-Year Waste Management Plan cc: Ed Mussler - NCDEQ Shannon Aufman - NCDEQ Larry Frost - NCDEQ Evan Andrews - Duke Energy Ed Sullivan – Duke Energy North Carolina Waste Management Plan 2017 Update 526 South Church Street Charlotte, North Carolina 28202 March 23, 2017 Duke Energy NC Ten-Year Waste Management Plan 2017 Update Table of Contents 1.0 Overview ........................................................................................................................ 1 2.0 Waste Management Strategy ......................................................................................... 1 2.1 Fly Ash ........................................................................................................................... 2 2.2 Bottom Ash ..................................................................................................................... 2 2.3 Flue Gas Desulphurization (FGD) Residue ..................................................................... 2 3.0 Future Ash Beneficiation Projects ................................................................................... 3 List of Abbreviations & Acronyms BTU British Thermal Unit CCP Coal Combustion Products CCP TS Duke Energy Coal Combustion Products & Technical Support CCR Coal Combustion Residuals NCDEQ North Carolina Department of Environmental Quality DWM Division of Waste Management FGD Flue Gas Desulfurization PTO Permit to Operate Duke Energy NC Waste Management Plan 2017 Update Page 1 of 4 1.0 Overview In accordance with North Carolina Administrative Code Section 130A-309.09D(c); A generator of industrial solid waste that owns and operates an industrial solid waste facility for the management of industrial solid waste generated by that generator shall develop a Waste Management Plan. This plan shall be updated at least every three years and be provided to the North Carolina Department of Environmental Quality (DEQ) upon request. This Duke Energy (Duke) Solid Waste Management Plan pertains to landfills at operational coal combustion facilities: • Allen Steam Station Retired Ash Basin Landfill (RAB Landfill) Permit No. 3612 • Belews Creek Steam Station Craig Road Ash Landfill (Craig Road Landfill) Permit No. 8504 • Belews Flue Gas Desulfurization (FGD) Residue Landfill, Phase I (FGD Landfill) Permit No. 8505 • Cliffside Steam Station Coal Combustion Products (CCP) Landfill (CCP Landfill) Permit No. 8106 • Marshall Steam Station FGD Residue Landfill, Phase I, Cell 1 (FGD Landfill) Permit No. 1809 • Marshall Steam Station Industrial Landfill #1 (ILF 1) Permit No. 1812 • Mayo Steam Electric Plant Coal Combustion Product Landfill (Landfill) Permit No. 7305 • Roxboro Steam Electric Plant Landfill (Landfill) Permit No. 7302 And facilities that have landfills to support closure of ash basins at retired coal combustion facilities: • Dan River Steam Station Landfill (Under Construction) Permit No. 7906 • Sutton Electric Steam Plant Landfill (Under Construction) Permit No. 6512 The initial permits to operate (PTO) for the above-listed landfills were issued by the NCDEQ, Division of Waste Management (DWM), and are subject to review every five years. The Sutton and Dan River landfill facilities are anticipated to receive PTOs during the 2017 calendar year and therefore included in this Waste Management Plan. This Waste Management Plan presented is developed in accordance with GS 130A-309.09D. 2.0 Waste Management Strategy – Plans for Waste Reduction and Disposal The Duke Energy operational coal combustion facilities generate electric power by combustion of coal which produces fly ash, bottom ash, FGD residue (gypsum), and other coal combustion residuals (CCR) on an operational basis. The operation of a station and the quantity of CCR produced depends on interconnected power demands of the Duke system as a whole (including renewable power sources and facilities that produce energy through nuclear, hydroelectric, and natural gas sources). The quantity of ash generated at the coal combustion facilities depends on factors such as the operation of the plant, Duke Energy NC Waste Management Plan 2017 Update Page 2 of 4 the use of ash in by-products, the heat of combustion of the coal itself (measured in British Thermal Units (BTUs)), ash content of the coal, and the quantity of coal burned. The quantity of FGD residue (synthetic gypsum) produced depends on the sulfur content and volume of coal combusted. These factors typically vary over the course of a single year, causing fluctuations in the quantity and quality of ash and gypsum. The fuel chemistry also impacts the amount of CCR produced at each station. Additionally, the rise in natural gas powered electricity generation has led to speculation that coal generation facilities may see a more limited role in fulfilling the region’s electricity demand during this planning period. This prediction, coupled with increasing strength in the ash reuse markets is expected to increase the demand for ash used in byproducts, resulting in a decrease in the quantity of material disposed in the landfills. The aforementioned factors result in difficulty estimating future disposal and reuse volumes for CCR material. This Waste Management Plan is only intended to be an estimate based on information available at the time the report was generated. Duke’s Coal Combustion Products & Technical Support (CCP TS) Group was developed to seek markets and applications for use of coal combustion byproducts. This group continuously works toward maximizing the re-use of coal combustion byproducts. Marketing of combustion byproducts is Duke's primary effort towards waste reduction. Duke reports CCR production, excavation, and reuse annually in accordance with 15A NCAC 13B .1710. Table 1, below, summarizes CCR volumes produced, disposed, used in structural fill facilities, and alternatively used as described in 15A NCAC 13B .1708 for the past 4 years. It is the goal of the CCP TS Group to increase reuse to the maximum extent possible. As shown in Table 1, recent ash basin excavation projects resulting in re-use in addition to mining synthetic from historical landfills has resulted in total annual beneficial re-use greater than 100%. Re-use volumes will vary greatly over the next few years due to regulatory requirements included in the Coal Ash Management Act of 2014. Duke Energy NC Waste Management Plan 2017 Update Page 3 of 4 Table 1 - Historical CCR Beneficial Reuse Production CCR Material Year Ash (tons) Synthetic Gypsum (tons) Total CCR Produced Re-Used Disposed Produced Re-Used Disposed % Beneficially Reused 2016 1,296,824 1,602,819 2,247,347 1,148,712 1,572,019 35,696 130% 2015 1,698,218 1,369,679 1,081,593 1,579,276 1,407,994 249,698 85% 2014 2,562,279 1,351,136 1,211,143 1,717,268 1,298,208 419,060 62% 2013 2,181,627 1,589,832 591,795 1,563,410 1,316,997 246,413 78% Table 1 notes: 1. Information was obtained from Duke Energy annual reports required by 15A NCAC 13B .1710. 2. Data is provided by the NCDEQ fiscal year (July 1 - June 30) as required by 15A NCAC 13B .1710. 3. Produced ash includes estimate of CCR material sluiced to basins 4. Re-Used and disposed CCR material includes ash from basins. 5. 2013 was the first reporting period for the combined Duke Energy and Progress Energy thereby the start of this table. 2.1 Fly Ash Fly ash is a light airborne particulate that results from the combustion of pulverized coal. Fly ash reuse is mostly used as a replacement for other aggregates, such as Portland cement, in concrete production. During the Duke 2016 fiscal year, approximately 1,216,042 tons of fly ash was produced at Duke facilities in North Carolina. Approximately 37% of the fly ash produced was beneficially used in the concrete market. The CCP TS Group is continuing to pursue the beneficial use of fly ash. Duke anticipates that an improving regional economy will increase the demand for beneficial use of fly ash, resulting in a decrease in the quantity of material disposed in the landfills. 2.2 Bottom Ash Bottom ash is a heavier ash particle that falls to the bottom of the plant boilers during combustion. Bottom ash reuse mostly occurs in concrete block manufacturing. During the Duke 2016 fiscal year, approximately 221,064 tons of bottom ash were produced at Duke facilities in North Carolina. Approximately 26% of the bottom ash was beneficially used in the concrete market. The CCP TS Group is continuing to pursue the beneficial use of bottom ash produced. Duke believes that an improving regional economy will increase the demand for beneficial use, resulting in a decrease in the quantity of material disposed in the landfills. 2.3 Flue Gas Desulphurization (FGD) Residue The FGD systems at Duke's North Carolina coal generating facilities were designed to produce wallboard-quality synthetic gypsum enabling the material to be beneficially reused. Synthetic gypsum reuse occurs mostly in the wallboard industry but is also seen in agricultural markets as a substitute for natural gypsum. During the Duke 2016 fiscal year, approximately 1,380,432 tons of synthetic gypsum were produced at Duke facilities in North Carolina. Approximately 97% of the gypsum was beneficially used in the manufacturing of gypsum wallboard or agricultural uses. The CCP TS Group is continuing to pursue the beneficial use of synthetic gypsum. Duke believes that an improving regional economy Duke Energy NC Waste Management Plan 2017 Update Page 4 of 4 will increase the demand for wall-board, resulting in a decrease in the quantity of material disposed in the landfills. 3.0 Future Ash Beneficiation Projects North Carolina General Statute 130A-309.216 Ash beneficiation projects, was ratified as part of House Bill 630 on July 1, 2016, and signed into law on July 14, 2016. NCGS 130A-309.216 requires an impoundment owner to identify at least three sites capable of processing 300,000 tons annually of ash suitable for cement processing purposes. These facilities are anticipated to increase coal combustion material available for re-use in the concrete industry.